Cereal-based batter comprising milk proteins for coating food products

Abstract: A food product having a crisp texture, golden brown appearance and fresh fired taste of conventionally-fried foods, comprising a food substrate coated with a cereal-based batter containing a non-gelling milk protein in which the batter has a solids level of at least 30 percent by weight and provides at least about 0.2 percent by weight of the non-gelling milk protein.

Description: BACKGROUND OF THE INVENTION Consumers develop preferences for particular types of food based upon texture, ie the tactile experience caused caused by the food in their mouths in conjunction with the food's distinct visual, physical and chemical characteristics. For example, fried, battered and battered/breaded foods are extremely popular because so many people have developed a liking for the crisp texture, golden brown appearance, and fresh fried taste of such foods. Unfortunately, once prepared, the crisp texture, golden brown appearance, and fresh fried taste of conventionally fried foods are difficult to maintain. This problem is particularly acute in situations such as those encountered in fast food restaurants, where battered and battered/breaded foods are fried up and then held for a period of time before they are purchased and consumed. This problem is also of concern with respect to frozen and refrigerated battered/breaded foods which are purchased by consumers for final preparation in the home. Therefore, it would be highly desirable to develop fried battered and battered/breaded foods which have the crisp texture, golden brown appearance, and fresh fried taste of conventionally fried foods, yet can be stored after preparation without losing these desirable organoleptic properties. US patent No. 3 830 941 discloses a coating for popcorn, corn chips and potato chips comprising an oil/water dispension including a starch hydrolysate and a protein which is dried to form a glaze. European Patent Publication No. O 219 425 discloses two cookie dough compositions used to form a cookie with a chewy centre and a crunchy exterior. The dough is cereal based and includes casein. US Patent No. 3 323 922 discloses a coating to protect food from air and moisture which comprises a film forming substance, a plasticiser and a liquid which is immiscible in the plasticiser. The coating is applied to the food and allowed to dry; no cooking is required. JP 5 3121948 discloses a liquid mixture comprising edible oil, flour, water, an emulsifier, egg white and sodium casein for use in preparing ready fried frozen tempura. International patent publication No. WO93/15619 relates to the application of a film to a dry already breaded product. Batters and breadings in Food Processing pages 104,105,175,176, and 234-236 discloses the effects on the different ingredients in batters and breadings and discloses the feature of batters being applied at 30-50% solids content. SUMMARY OF THE INVENTION The present invention is directed to battered and battered/breaded foods and to methods of their preparation. More particularly, the present invention is directed to battered and battered/breaded foods with a crisp texture, a golden brown appearance and a fresh fried taste which retain these desirable characteristics even if stored for a period of time after they are fully prepared but before they are consumed. The present invention is also directed to a method for making such unusually stable battered and battered/breaded foods. Accordingly, the present invention relates to a parfried or fully cooked food product obtainable by a process comprising: producing a cereal-based hydrated batter containing dry ingredients, added edible fat, water and a non-gelling milk protein, wherein some or all of the edible fat is creamed onto some or all of the dry ingredients before the dry ingredients are hydrated, and wherein said hydrated batter has a total solids level of at least about 30 percent by weight; coating the batter onto a food substrate, with the batter being picked up on the substrate at a level sufficient to provide at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product; and at least parfrying the coated substrate to set the coating; said non-gelling milk protein being a caseinate; wherein gelling proteins are excluded from the hydrated batter. The food product may include a breading as either an overcoat or an undercoat. Additionally, where necessary to eliminate uncooked interface, the batter will include at least about 2 percent by weight of added edible fat. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a close-up photograph of the caseinate-containing batter-coated chicken pieces described in Example 3 illustrating the crisp, crunchy fracturable coating and golden brown appearance achieved in that product; and Figure 2 is a caseinate-free batter-coated chicken piece prepared as described in Example 3. DETAILED DESCRIPTION Food Substrates The food substrates which may be used in the practice of this invention include meat, poultry, seafood, cheese, vegetables, fruit, cereal-based products, and nuts. Examples of cereal-based products include pizza doughs, biscuit doughs, grain-based snacks, veggie burgers, and breakfast cereals. Batters and Breadings Any conventional cereal-based batter can be used in the practice of this invention including tempura batters and batters typically used with undercoatings or overcoatings of flour or breadings. The batters will be applied to the substrates by conventional techniques such as by submerging the substrate in the batter, passing the substrate under a batter waterfall or spraying the batter onto the substrate. A typical tempura batter would compromise the following ingredients, expressed in percentage by weight of the dry mixture: Ingredient Range of Concentration Preferred Concentration wheat flour 15-76% 40% yellow corn flour 0-60% 40% modified and/or unmodified food starch 0-75% 10% salt 0-15% 3.5% sugars 0-20% 4.5% leavening 0.25-4% 2% Tempura batters like those described above may be prepared by mixing the dry components and then combining with water in a ratio by weight of water to dry ingredients of from about 2:1 to 1:1.25 and preferably about 1.125:1. The present invention may also be used with batters intended for use with undercoatings and/or overcoatings of flour and breadings. A typical such batter will compromise the following ingredients, expressed in percentage by weight of the dry mixture. Ingredient Range of Concentration Preferred Concentration yellow corn flour 0-20% 15% modified and/or unmodified food starch 10-90% 70% wheat flour 0-20% 10% salt 2-10% 3% sugars 0-5% 1.75% leavening 0-1% 0.25% Again, these batters may be prepared by mixing the dry ingredients and then combining with water. The ratio by weight of water to dry ingredients may range from about 2:1 to 1:1 and preferably will be about 1.25:1. The breading used with the above batter may be chosen from the group comprising unhydrated, raw, fully-cooked or partially-cooked cereals such as wheat flour, rice flour, corn flour, bread crumbs or corn flakes. The breading, which preferably is ground to at least 100 percent through a U.S. No. 3 sieve, will be applied by conventional procedures (i.e. dusting or tumbling), either before or after application of the batter. Application of the breading after the batter is preferred when the greatest texture is desired in the final product. In all cases, the final batter, before application, must have a total solids level of at least about 30 percent by weight, preferably will have a total solids level of from about 30 to 60 percent by weight, and most preferably will contain at least about 45 percent by weight total solids. The Texturizing Agents The batter must include a texturizing agent in the form of a non-gelling milk protein and, added edible fat above and beyond the fat already inherently present in the dry ingredients or conventionally added as a processing aid to ensure uniform distribution of the ingredients (which together typically amount to up to about 0.25 percent by weight of the hydrated batter). The two components must be added separately to the mixture and, as also explained below, the fat will be creamed onto the dry batter ingredients. The level of the milk protein in the final hydrated batter must be in the range of from about 0.6 to 8.0 percent by weight, preferably will be at a level of about 1.0 to 6.0 percent by weight and most preferably will be at level of about 3 percent by weight. Additionally, the pick-up of the batter on the substrate must be sufficient to provide at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product. Preferably, the pick-up will be about 0.2 to 3.0 percent by weight and most preferably it will be about 1 percent by weight. The milk protein must be a derivative of casein such as sodium caseinate, calcium caseinate, or potassium caseinate. Sodium caseinate is the preferred milk protein. Milk protein isolate may also be used because of its caseinate content, but it is less preferred than caseinates. Gelling proteins, such as albumin and whey, are not effective in the practice of the invention. In addition to the noted non-gelling milk proteins, in applications where a gelatinous uncooked interface is otherwise formed, the texturizing agent should include added edible fat. Typical useful edible fats include vegetable oil, hydrogenated vegetable oil, plant oils and animal fats. The preferred edible fat is hydrogenated soybean oil. The combination of non-gelling milk protein and added fat will reduce or eliminate the uncooked interface which tends to form when there is a high pick-up of the batter (more than about 25 percent by weight based on the coated product before processing) and when a high moisture substrate (more than about 60 percent moisture by weight of the substrate) is used. The level of added edible fat will be at least about 2 percent by weight of the final hydrated batter. Preferably, the added edible fat will be at a level of about 2 to 4 percent by weight and most preferably it will be at a level of about 3 percent by weight. Some or all of the added fat is "creamed" onto some or all of the dry ingredients before they are hydrated to make the batter. This "creaming" step makes the dry ingredients somewhat hydrophobic so that there is reduced swelling and therefore reduced viscosity in the final batter, at a given solids level. As a result, higher solids levels may be used without making the batter too thick to handle. Also, the reduced moisture at a given solids level results in a reduction in the formation of uncooked interface in the finished product. The "creaming" step, for example, may be carried out by high shear blending of some or all of the dry ingredients with the fat in, eg., a fluidized bed blender or a ribbon blender. Preparation of Foods with Enhanced Crispiness Battered and battered/breaded foods with enhanced crispness may be prepared for eating in accordance with the present invention by: 1) Batter-coating and optionally breading the substrate, parfrying, optionally freezing or refrigerating the coated/parfried product, and completely cooking; 2) batter-coating and optionally breading the substrate, freezing or refrigerating the coated product, and completely cooking; or 3) batter-coating and optionally breading the substrate, optionally parfrying, fully cooking, and optionally freezing or refrigerating the coated product and reheating. When the substrate is coated with batter and then parfried to set the coating, the parfrying step should be carried out at a temperature in the range of about 130-210°C for about 15-60 seconds and preferably at a temperature of about 200°C for about 30 seconds. The resulting product then may be stored under refrigeration at about 3 to 7°C or frozen at about 0 to -40°C. When it is desired to finalize the parfried product for eating, it will be cooked to completion by conventional means such as by baking in a conventional oven, a convection oven or a microwave oven, by steaming, by deep-fat frying, or sauteing. Coated substrates which are not parfried but rather are refrigerated or frozen after coating will require at least partial frying in order to obtain the desired fried appearance in the final product. Thus, such batter-coated substrates will be taken from the refrigerator or freezer and then fully cooked by deep-fat frying or sauteing. When it is desired to prepare the previously fully cooked coated substrates, they need only be heated up to eating temperature. Products prepared in accordance with this invention are particularly well adapted for holding under a heat lamp or in a warming cabinet after preparation. In other words, once products prepared in accordance with this invention are fully cooked, they may be held for from 15 minutes to one hour or more under a heat lamp, in a warming cabinet or in some other heat-holding apparatus without significant deterioration of the crisp texture, golden brown appearance and fresh fried taste of the product. EXAMPLES The following examples are intended to be illustrative of the present invention and to teach one of ordinary skill in the art how to make and use the invention. These examples are not intended to limit the invention or its protection in any way. Example 1 In this example, the effectiveness of various different proteins on the crispness of an ovenized batter coating was examined. The proteins evaluated included sodium caseinate, calcium caseinate, lactalbumin, milk protein isolate (total milk protein-mixture of whey protein and caseinates), whey protein concentrate, and soy protein isolate. Protein at a 1.5% by weight level based on the final hydrated batter was dry blended with the other batter components (wheat flour, hydrogenated vegetable oil, leavening, sugar, salt, and corn flour) and mixed at a 1:1 ratio by weight with cold water. The shortening constituted about 2.14% by weight of the final hydrated batter. Pollack fish portions (about 0.037kg (1.3oz.)) were dipped into the batter (pick-up about 50% by weight of the coated product before processing) and parfried for 30 seconds at about 200°C. The batter-coated fish portions were then frozen for about 18 hours. The frozen, battered fish portions were then reconstituted by cooking in a regular household oven for 30 minutes at about 205°C. The reconstituted portions were examined and it was found that those coated with batters made with calcium caseinate and sodium caseinate exhibited a unique, delicate crispness in comparison to the control, which contained no added protein. The milk protein isolate produced a significantly lesser texture enhancement. Finally, the whey and soy protein-containing batters produced the same soggy texture seen in the control batter-coated products. Example 2 In this example the effectiveness of batters containing texturizing agents comprising caseinate/fat combinations, as well as caseinate-free and fat free batters were examined and compared. The substrate used in each case was frozen pollack fish weighing about 0.037kg (1.3oz.). The batters set out in Table 1 were used in the tests. The fish portions were coated with the batter by dipping and then parfried in a deep fat fryer for 30 seconds at about 200°C. After the flash-frying step, the pick-up of batter for each sample was determined. The batter-coated products were then stored in a freezer at about -40°C for three days after which they were reheated in an oven at about 220°C for 15 minutes. The finished products were evaluated for texture, the presence or absence of interface, and color. The results are set out in Table II. The data set out in Table II demonstrates the following: 1. While the use of caseinate improved the texture of the product after oven reconstitution, there was no reduction of uncooked interface. 2. The use of a texturizing agent comprising a combination of caseinate and fat (either creamed or non-creamed to the flour) substantially improved the texture of the finished product and minimized the amount of uncooked interface. 3. Batters without fat or caseinate showed significantly inferior texture and undesirable interface, as compared to those containing the caseinate/fat texturizing agent. Example 3 In this example, two sets of batter-coated product were prepared by dipping boneless chicken pieces in two batters, the first comprising, on a dry basis, 14% sodium caseinate and 86% wheat starch and the second comprising 100% wheat starch. The dry mixes were combined with water on a weight basis of 1.5 parts water to 1 part dry mix. Batter pick-up on the chicken pieces was about 20% by weight based on the coated pieces before processing. Once coated, the chicken pieces were lightly coated with flour, parfried at 200°C for about 30 seconds, frozen, and then reheated in a deep fat fryer at about 180°C for four minutes. Close-up photographs were then taken and are attached as Figures 1 and 2, which correspond respectively to the caseinate-containing batter-coated chicken pieces and to the caseinate-free batter-coated chicken pieces. These photographs demonstrate the crisp, crunchy, fracturable coating and golden brown appearance achieved in the caseinate-containing product and the far less desirable appearance and texture achieved in the caseinate-free product. Example 4 Storage under a heat lamp was examined in this example. Marinated, bone-in chicken pieces were coated with a 4- pass system (batter-breading-batter-breading), par-fried and individually quick-frozen. The hydrated batter contained 33.2% modified food starch, 1.8% sodium caseinate, and 65% water. The batter delivered approximately 0.5% sodium caseinate to the final product. The battered and breaded frozen chicken was reconstituted in an open fryer and fully cooked. The product was then held under a heat lamp where it was observed to remain very crispy throughout the two hour holding period. Similar products made with a traditional sodium caseinate-free coating system and held under a heat lamp were found to lose crispness after approximately 30 minutes. Example 5 This example demonstrates the creaming of 8% by weight vegetable fat onto 92% by weight wheat flour. The wheat flour was added to the shortening and the mixture is mixed for 2 minutes at high speed in a Littleford Blender model FM130 (Registered Trade Mark), used to cream the shortening for one minute at high speed (0.085m 3 ) (3 cubic feet) @ 155 rev/min. The resulting product was used in a batter prepared in accordance with the invention. The viscosity of the batter was significantly reduced from that obtained with the same batter in which the fat was not creamed onto the flour, but rather was added separately. While the present invention is described above in connection with preferred or illustrative embodiments, these embodiments are not intended to be exhaustive or limiting of the invention. Rather, the invention is intended to cover all alternatives, modifications and equivalents included within its spirit and scope, as defined by the appended claims.

Claims: A parfried or fully cooked food product obtainable by a process comprising: producing a cereal-based hydrated batter containing dry ingredients, added edible fat, water and a non-gelling milk protein, wherein some or all of the edible fat is creamed onto some or all of the dry ingredients before the dry ingredients are hydrated and wherein said hydrated batter has a total solids level of at least about 30 percent by weight; coating the batter onto a food substrate, with the batter being picked up on the substrate at a level sufficient to provide at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product; and at least parfrying the coated substrate to set the coating; said non-gelling milk protein being a caseinate; wherein gelling proteins are excluded from the hydrated batter. The food product of claim 1 including a breading. The food product of claim 2 in which the breading is coated onto the batter as an overcoat. The food product of claim 2 in which the breading is applied to the food substrate as an undercoat. The food product of claim 1 in which the food substrate is chosen from the group consisting of meat, poultry, seafood, cheese, vegetables, fruit, cereal-based products and nuts. The food product of claim 5 in which the cereal-based products include pizza doughs, biscuit doughs, grain-based snacks, veggie burgers, and breakfast cereals. The food product of claim 1 including an undercoating or overcoating of flour and breadings in which the dry ingredients comprise about 15-76 percent by weight wheat flour, about 0-60 percent by weight yellow corn flour, about 0-75 percent by weight modified and/or unmodified food starch, about 0-15 percent by weight salt, about 0-20 percent by weight sugars and about 0.25 percent by weight leavening. The food product of claim 1 including an undercoating or an overcoating of flour or breadings in which the dry ingredients comprise about 0-20 percent by weight yellow corn flour, about 10-90 percent by weight modified and/or unmodified food starch, about 0-20 percent by weight wheat flour, about 2-10 percent by weight salt, about 0-5 percent by weight sugar, and about 0-1 percent by weight leavening. The food product of claim 1 in which the hydrated batter has a total solids level of from about 30-60 percent by weight. The food product of claim 1 in which the non-gelling milk protein is chosen from the group consisting of sodium caseinate, calcium caseinate, and potassium caseinate. The food product of claim 1 in which the level of non-gelling milk protein in the hydrated batter ranges from about 0.6 to 8.0 percent by weight. The food product of claim 1 in which the pick-up of the hydrated batter on the food substrate is sufficient to provide about 0.2 to 3.0 percent by weight of the non-gelling milk protein based on the weight of the coated product. The food product of claim 1 wherein at least 2 percent by weight of edible fat is included in the hydrated cereal based batter based on the weight of the batter. A method of preparing a food product comprising: coating a food substrate with a cereal based hydrated batter containing added edible fat and a non-gelling milk protein being a caseinate in which the hydrated batter has a total solids level of at least about 30 percent by weight and provides at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product; parfrying; and completely cooking; wherein gelling proteins are excluded from the hydrated batter and the hydrated batter is produced by a process comprising the step of creaming some or all of the edible fat onto some or all of the dry ingredients of the batter before said dry ingredients are hydrated. A method of preparing a food product comprising: batter-coating a food substrate with a cereal based hydrated batter containing added edible fat and a non-gelling milk protein being a caseinate in which the hydrated batter has a total solids level of at least about 30 percent by weight and provides at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product; freezing or refrigerating the coated product; and completely cooking, wherein completely cooking includes at least partial frying; wherein gelling proteins are excluded from the hydrated batter, and the hydrated batter is produced by a process comprising creaming some or all of the edible fat onto some or all of the dry ingredients of the batter before the dry ingredients are hydrated. A method of preparing a food product comprising: batter-coating a food substrate with a cereal based hydrated batter containing added edible fat and a non-gelling milk protein being a caseinate in which the hydrated batter has a total solids level of at least about 30 percent by weight and provides at least about 0.2 percent by weight of the non-gelling milk protein based on the weight of the coated product; fully cooking wherein fully cooking includes at least partial frying; and re-heating; wherein gelling proteins are excluded from the hydrated batter and the hydrated batter is produced by a process comprising creaming some or all of the edible fat onto some or all of the dry ingredients of the batter before the dry ingredients are hydrated.

Inventors: BAUR JOACHIM, BERNACCHI DONALD B, DARLEY KENNETH S, DONHOWE IRENE GREENER, JANDA JOSEPH J, MARTIN JAMES R, BAUR, JOACHIM, BERNACCHI, DONALD B., DARLEY, KENNETH S., DONHOWE, IRENE GREENER, JANDA, JOSEPH J., MARTIN, JAMES R.
Applicants: GRIFFITH LAB WORLDWIDE INC, GRIFFITH LABORATORIES WORLDWIDE, INC.
Application year: 1994
Main classification: A23P1
IPC codes: A23J3, A23L1